Polycrystalline diamond compacts and related methods

Patent metadata

Field	Value
Publication number	US-9889541-B2
Application number	US-201414147241-A
Country	US
Kind code	B2
Filing date	Jan 3, 2014
Priority date	Oct 30, 2008
Publication date	Feb 13, 2018
Grant date	Feb 13, 2018

Abstract

Embodiments of the invention relate to polycrystalline diamond compacts (“PDCs”) and methods of fabricating polycrystalline diamond tables and PDCs in a manner that facilitates removal of metal-solvent catalyst used in the manufacture of polycrystalline diamond tables of such PDCs.

First claim

What is claimed is:

1. A polycrystalline diamond compact, comprising:
a substrate; and
a polycrystalline diamond table including a working surface and an opposing interfacial surface directly bonded to the substrate, the polycrystalline diamond table including bonded diamond grains defining a plurality of interstitial regions, the polycrystalline diamond table further including:
a first volume of the polycrystalline diamond table including the bonded diamond grains extending inwardly from the working surface;
a second volume of the polycrystalline diamond table including the bonded diamond grains extending inwardly from the interfacial surface;
a metal-solvent catalyst and at least one sacrificial material disposed in at least a portion of the plurality of interstitial regions;
wherein the at least one sacrificial material comprises a material different than that of the metal-solvent catalyst, the at least one sacrificial material including a plurality of sacrificial particles, at least one reaction product of the plurality of diamond grains and the plurality of sacrificial particles, or combinations thereof;
wherein the at least one sacrificial material is present in the first volume and the second volume of the polycrystalline diamond table in a pre-leaching concentration of greater than 0 weight % to about 5 weight % of the first volume and the second volume prior to leaching the first volume;
wherein the at least one sacrificial material is present in the first volume in a concentration such that the first volume exhibits a post-leaching concentration of the metal-solvent catalyst of less than 0.85 weight % of the first volume, and the second volume includes the pre-leaching concentration of the at least one sacrificial material, after leaching the first volume.

2. The polycrystalline diamond compact of claim 1 wherein the post-leaching concentration of the metal-solvent catalyst in the first volume is about 0.20 weight % to about 0.50 weight % after leaching.

3. The polycrystalline diamond compact of claim 1 wherein the post-leaching concentration of the metal-solvent catalyst in the first volume is about 0.50 weight % to about 0.78 weight %.

4. The polycrystalline diamond compact of claim 1 wherein the metal-solvent catalyst includes at least one member selected from the group consisting of iron, nickel, and cobalt.

5. The polycrystalline diamond compact of claim 1 wherein the at least one sacrificial material includes tungsten carbide.

6. The polycrystalline diamond compact of claim 1 wherein the pre-leaching concentration of the at least one sacrificial material is about 1 weight % to about 5 weight %.

7. The polycrystalline diamond compact of claim 1 wherein the pre-leaching concentration of the at least one sacrificial material is about 1.5 weight % to about 2.5 weight %.

8. The polycrystalline diamond compact of claim 1 wherein the first volume extends to a depth of about 50 μm to about 500 μm from the working surface.

9. The polycrystalline diamond compact of claim 1 wherein the first volume extends to a depth of at least about 200 μm from the working surface.

Assignees

• Us Synthetic Corp

Inventors

• Sani Mohammad N
• Gonzalez Jair J
• Dadson Andrew E
• Mukhopadhyay Debkumar

Classifications

• Y10T428/12028

  Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.] · CPC title

• Y10T428/24355

  Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] · CPC title

• Y10T428/12056

  Entirely inorganic · CPC title

• B24D3/10 Primary

  for porous or cellular structure, e.g. for use with diamonds as abrasives · CPC title

• C22C26/00

  Alloys containing diamond {or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes} · CPC title